Fork disassembly

georelle · Posted: September 24, 2007, 10:55 pm Post subject: Fork disassembly

Ok I have read all I could on here about getting those %^$%^$ hex bolts off the front fork lowers but I am still having problems. I have a '76 and the damper turns..... of course. I mean why wouldn't it? I am no rocket surgeon, but whomever designed these front forks just didn't think this one through. I can't use the 7/16' threaded rod tool trick because the '76s' are not compatible with that tool. I can't drill the hex nuts off because the damper turns when I try to drill. Sooo I was thinking what if I got a screw that was a little longer then the little drain screw and jammed that into the damper then tried to remove the hex bolt. Anyone tried this, or have any other suggestions? Please!
My only other alternative is to replace the seals using the fork bomb method as described on the wiki page. I do have a 4x4 in the garage and some "friends" who would pay to see my attempt it.

Thanks to all for any help.
Georelle

WayneMeuir · Posted: September 25, 2007, 8:52 am Post subject: Re: Fork disassembly

Are you using an impact wrench to remove them? If not, get one and try it. Usually the impact turns faster than the damper rod can turn and it screws right out.

Wayne

georelle · Posted: September 25, 2007, 10:00 am Post subject: Re: Fork disassembly

Wayne
That is the one thing I have not tried. I did try my power drill which didn't quite cut it. I cut off a allen wrench and chucked it. I can put that allen in a socket to us in with an impact. I have found a co-worker today who lives close by who has an impact and I will try that this eve. I will report on the results.
I think once I get these apart the damper will be modified to make it easier next time I need to get into them.
I am still curious about the drain screw idea.

Geo

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

The Yamaha dealer in Buffalo just did both my fork seals for $100.
I consider it money well spent - I have seen a lot of posts about the problems with changing fork seals.

All pride aside - you may just want to pay to have someone do this one.

That way if it leaks - you've got someone to take it back to.

georelle · Posted: September 25, 2007, 2:01 pm Post subject: Re: Fork disassembly

Jimdi
I did consider it after reading some of the posts here. It really should be a simple process to replace the fork seals. I have done it on my '02 suzuki marauder with inverted forks. When those leak they need to be replaced asap. There are alot of things that would be easier to have the dealer do but I am doing a complete rebuild and want to keep the overall cost in line. So $10.00 vs $100.00 I'll put up with the headaches for now anyway. Actually since I am the one who will be riding it I trust my work more then the dealers.

Georelle

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

I have always done all the work on my bike as well -
but when my forks started leaking - and I started researching the process - the special tool I needed - it just wasn't worth it.

Plus here in NY if the forks are leaking it won't pass state inspection -
and since I wanted to ride I just bit the bullet.

ghostyder · Posted: September 25, 2007, 3:19 pm Post subject: Re: Fork disassembly

Im kinda surprised by how often this comes up. Impact wrench is the only answer and its amazing how easily it comes apart with the right tool after all the struggles without it.

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

Yes - part two of that is a good impact wrench - I had a worthless cambell hausfeld - wasn't worth a sh!t.

Got a good craftsman - it was like night and day - nothing better for shock bolts and other stubborn situations.

georelle · Posted: September 25, 2007, 4:21 pm Post subject: Re: Fork disassembly

Well I was looking for an alternative to the impact wrench. I've got the compressor but not the impact. And was wondering about the drain screw idea and if anyone has attempted that. For those of us who do not have a good impact wrench laying around. When I take the drain screw out of the lower fork and turn the hex nut I can see it turning in there and it seems with a longer screw you could jam the damper enough to get the hex nut out. I am surprised no one has attempted it, or atleast no one is admitting it.
But now that I have access to an impact I will try that.
Thanks for the feedback
Georelle

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

Before you risk breaking or damaging something that may cost you more in the long run consider this if you don't have the correct tool or can't rent one...

any auto part stores now loan tools..

Do you know any mechanics who would bust it loose for you with their impact wrench for a couple of bucks or a six pack or beer....

Take it to a machine shop - I bet they would only charge about $10 to take it apart 0-

Or hey - now that it's off the bike take it to the dealer - I bet he would be a hell of a lot cheaper when it's off the bike.

Spending a little is better than wrecking a part and having to buy a new fork.

georelle · Posted: September 25, 2007, 4:53 pm Post subject: Re: Fork disassembly

"Spending a little is better than wrecking a part and having to buy a new fork."

I totally agree. I am proceeding with caution. Shocked

georelle · Posted: September 25, 2007, 10:04 pm Post subject: Re: Fork disassembly

Success! And once again confirmation the impact wrench is the way to go. Now that I have the fork apart I can see that using a screw to jam the damper probably would not have been a good idea. I can also see now that the top end of the damper is not perfectly round but has two flat spots on it. I think a tool to fit over it is a possibility.

Once again thanks to all for the assistance.

A note to those who might read this in the future: USE AN IMPACT! If you do not have one take your forks to your mechanic and have him spin the hex bolts out for you. If he charges you pay him then find a new mechanic. For a tool to get at the hex bolt I cut off an allen wrench and put it in a socket. They say it is 8mm but I found 5/16" fit better.

Georelle

helltaco · New Member Joined: Sep 20, 2007 Posts: 5

georelle wrote:

Success! And once again confirmation the impact wrench is the way to go. Now that I have the fork apart I can see that using a screw to jam the damper probably would not have been a good idea. I can also see now that the top end of the damper is not perfectly round but has two flat spots on it. I think a tool to fit over it is a possibility.

The shop manual says:
"The damper rod has flats milled on it, and a piece of tubing with the end flattened can be passed down through the fork stanchion to hold it. The overall diameter of the head is 12mm, with the flats measuring 10mm across. A piece of tubing having an internal diameter of 1/2" proves ideal for this purpose."

georelle · Posted: October 15, 2007, 10:29 pm Post subject: Re: Fork disassembly

Thanks HT. Unfortunately my Clymer manual did not have that info. But the impact wrench did do the trick. The forks are back together and seem alright. We will see when I get the project done how they perform.

G

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